# Manufacturing Files for PCBWay

## Required Files for PCB + Assembly Order

### 1. Gerber Files (from KiCad)

Export from KiCad PCB editor: `File → Fabrication Outputs → Gerbers`

Required layers:
- `SN-L00-F_Cu.gbr` - Front copper
- `SN-L00-B_Cu.gbr` - Back copper
- `SN-L00-F_SilkS.gbr` - Front silkscreen
- `SN-L00-B_SilkS.gbr` - Back silkscreen
- `SN-L00-F_Mask.gbr` - Front soldermask
- `SN-L00-B_Mask.gbr` - Back soldermask
- `SN-L00-Edge_Cuts.gbr` - Board outline
- `SN-L00-PTH.drl` - Plated through holes
- `SN-L00-NPTH.drl` - Non-plated through holes

**Settings:**
- Format: Gerber X2 (or RS-274X)
- Drill format: Excellon
- Units: mm
- Coordinate format: 4.6

### 2. BOM (Bill of Materials)

See `BOM_PCBWay.csv` - formatted for PCBWay assembly.

### 3. CPL (Component Placement List)

See `CPL_PCBWay.csv` - component positions for pick and place.

Export from KiCad: `File → Fabrication Outputs → Component Placement`

## PCBWay Order Settings

### PCB Specifications

| Parameter | Value |
|-----------|-------|
| Layers | 2 |
| Dimensions | 28mm × 100mm |
| Quantity | 5 (minimum) |
| Thickness | 1.6mm |
| Surface Finish | HASL (lead-free) or ENIG |
| Soldermask | Black |
| Silkscreen | White |
| Copper Weight | 1oz (35µm) |
| Min Track/Space | 0.2mm / 0.2mm |
| Min Hole | 0.3mm |

### Assembly Options

| Parameter | Value |
|-----------|-------|
| Assembly Side | Top + Bottom (or Top only) |
| Unique Parts | ~12 |
| SMD Parts | ~16 placement points |
| Through-hole | 2 (jacks, power header) |

### Parts Sourcing

- **LCSC parts**: Most SMD components (auto-sourced)
- **Customer supplied**: RP2040-Zero, OLED module (hand-solder)
- **Thonkiconn jacks**: May need to source separately

## Cost Estimate (5 units)

| Item | Cost |
|------|------|
| PCB fabrication | $5-10 |
| SMD assembly | $15-25 |
| LCSC components | $20-30 |
| Shipping | $15-25 |
| **Total** | **$55-90** |

*Prices vary by quantity and shipping speed*

## Order Checklist

- [ ] Export Gerbers from KiCad
- [ ] Generate drill files
- [ ] Export component placement (CPL)
- [ ] Verify BOM has correct LCSC part numbers
- [ ] Zip Gerbers + drill files
- [ ] Upload to PCBWay
- [ ] Select "PCB Assembly" option
- [ ] Upload BOM and CPL
- [ ] Review part matching
- [ ] Confirm order

## Files in this Directory

```
manufacturing/
├── README.md           # This file
├── BOM_PCBWay.csv      # Bill of materials for assembly
├── CPL_PCBWay.csv      # Component placement list
└── gerbers/            # Gerber files (after KiCad export)
    └── .gitkeep
```